Flexible spring member as well as gas spring assembly and method of manufacture

ABSTRACT

Flexible spring members can be dimensioned for securement to an associated gas spring end member. The flexible spring member can be at least partially formed from elastomeric material. The flexible spring member can also include a marking disposed along a surface thereof that includes one or more indicia. The marking can be at least partially formed by an indicia layer and an outer layer. The indicia layer can include one or more quantities of material that at least partially form the one or more indicia. The outer layer can be formed from a quantity of material that is disposed overtop of the indicia layer such that the one or more indicia of the indicia layer are substantially encapsulated. Gas spring assemblies, suspension systems, methods of manufacture and manufacturing systems are also included.

This application is a divisional of U.S. patent application Ser. No.13/959,661, filed on Aug. 5, 2013, which claims the benefit of U.S.Provisional Patent Application No. 61/679,621, filed on Aug. 3, 2012,the entire contents of each of which is hereby incorporated herein byreference.

BACKGROUND

The subject matter of the present disclosure broadly relates to the artof gas spring devices and, more particularly, to flexible spring membersthat includes a flexible wall and one or more indicia marked along asurface of the flexible wall. Such flexible spring members can beincluded in or otherwise form a part of gas spring assemblies, and oneor more of such gas spring assemblies can be included in or otherwiseform a part of suspension systems. Methods of manufacturing flexiblespring members in accordance with the subject matter of the presentdisclosure are also included.

The subject matter of the present disclosure may find particularapplication and use in conjunction with components for wheeled vehicles,and will be shown and described herein with reference thereto. However,it is to be appreciated that the subject matter of the presentdisclosure is also amenable to use in other applications andenvironments, and that the specific uses shown and described herein aremerely exemplary. For example, the subject matter of the presentdisclosure could be used in connection with gas spring assemblies ofnon-wheeled vehicles, support structures, height adjusting systems andactuators associated with industrial machinery, components thereofand/or other such equipment. Accordingly, the subject matter of thepresent disclosure is not intended to be limited to use associated withgas spring suspension systems of wheeled vehicles.

Wheeled motor vehicles of most types and kinds include a sprung mass,such as a body or chassis, for example, and an unsprung mass, such astwo or more axles or other wheel-engaging members, for example, with asuspension system disposed therebetween. Typically, a suspension systemwill include a plurality of spring devices as well as a plurality ofdamping devices that together permit the sprung and unsprung masses ofthe vehicle to move in a somewhat controlled manner relative to oneanother. Movement of the sprung and unsprung masses toward one anotheris normally referred to in the art as jounce motion while movement ofthe sprung and unsprung masses away from one another is commonlyreferred to in the art as rebound motion.

In some cases, the spring devices of a suspension system of a wheeledmotor vehicle can be of the type referred to as a gas spring assembly,such as commonly have opposing end members with a flexible spring membersecured therebetween in a substantially fluid-tight manner to form aspring chamber. It is generally desirable for gas spring assemblies toinclude identifying information thereon, such as manufacturer name,model number, serial number, batch or lot number, size characteristicsand/or load capacity, for example. In some cases, such information maybe molded or otherwise formed into a flexible wall of the flexiblespring member. In such cases, however, the identifying information willbe of the same color as the material from which the flexible wall ismade. As a result, the identifying information on the flexible wall isoften unreadable at distances of more than a few feet. Furthermore, theidentifying information on the flexible wall may be difficult to readeven at distances of a few feet or less.

In other cases, such identifying information may be printed directly ona flexible wall of the flexible spring member. Unfortunately, the typeand kind of marking compounds (e.g., ink) that are commonly used tendnot to be sufficiently durable to withstand the environmental conditionstypically associated with the use of gas spring assemblies on a motorvehicle suspension system. That is, exposure to matter such as water,salt, dirt and other compounds as well as exposure to atmosphericconditions such as oxygen (O₂), ozone (O₃) and UV radiation typicallycause the printed characters to be absorbed, washed off, faded orrendered otherwise unreadable. Thus, potentially causing a repairtechnician to have to undertake additional and, often, time consumingefforts to determine the identifying information, such as may be neededto procure a suitable replacement part or assembly, for example.

Notwithstanding the common practice of marking the flexible wall offlexible spring members of gas spring assemblies, it is believed that aneed exists to advance the art of gas spring assemblies by developingmarked flexible spring members having improved aesthetic appearanceand/or durability as well as methods and/or techniques for performingachieving the same, while still retaining comparable or improvedperformance, ease of manufacture, and/or cost of manufacture.

BRIEF SUMMARY

One example of a flexible spring member in accordance with the subjectmatter of the present disclosure can be dimensioned for securement to anassociated gas spring end member. The flexible spring member can be atleast partially formed from elastomeric material and can have at leastone of an inner surface and an outer surface. The flexible spring membercan also include a marking disposed along at least one of the innersurface and the outer surface that includes one or more indicia. Themarking can be at least partially formed by an indicia layer and anouter layer. The indicia layer can include one or more quantities ofmaterial that at least partially form the one or more indicia. The outerlayer can be formed from a quantity of material that is disposed overtopof the indicia layer such that the one or more indicia of the indicialayer are substantially encapsulated along the one of the inner surfaceand the outer surface.

One example of a gas spring assembly in accordance with the subjectmatter of the present disclosure can include a flexible spring memberand an end member. The flexible spring member can have a longitudinalaxis and can extend peripherally about the axis and betweenlongitudinally spaced-apart ends. The flexible spring member can be atleast partially formed from elastomeric material and have an innersurface and an outer surface. The flexible spring member can alsoinclude a marking disposed along one of the inner surface and the outersurface that includes one or more indicia. The marking can be at leastpartially formed by an indicia layer and an outer layer. The indicialayer can include one or more quantities of material that at leastpartially form the one or more indicia that are disposed on or along theone of the inner surface and the outer surface. The outer layer can beformed from a quantity of material that is disposed overtop of theindicia layer such that the one or more indicia are substantiallyencapsulated along the one of the inner surface and the outer surface.The end member can be secured across one of the longitudinallyspaced-apart ends such that a substantially fluid-tight connection canbe formed between the flexible spring member and the end member suchthat the flexible spring member and the end member can together at leastpartially define a spring chamber of the gas spring assembly.

One example of a suspension system in accordance with the subject matterof the present disclosure can include a pressurized gas system thatincludes a pressurized gas source and at least one control device. Thesuspension system can also include one or more gas spring assembliesaccording to the foregoing paragraph in fluid communication with thepressurized gas system.

One example of a method of manufacturing a gas spring assembly inaccordance with the subject matter of the present disclosure can includeproviding a flexible spring member that is at least partially formedfrom elastomeric material and has a surface. The method can also includeforming a marking having one or more indicia along the surface. Theaction of forming a marking can include applying one or more quantitiesof material on or along the surface to form an indicia layer that atleast partially forms the one or more indicia. The action of forming amarking can also include applying a quantity of material on or along thesurface to form an outer layer disposed overtop of the indicia layersuch that the one or more indicia are substantially encapsulated. Themethod can also include providing an end member and securing the endmember on or along the flexible spring member such that a substantiallyfluid-tight seal is formed therebetween.

One example of a system operative to manufacture a flexible springmember in accordance with the subject matter of the present disclosurecan include a base and a spindle rotatably supported on the base. Thesystem can also include support members dimensioned to receivinglyengage a flexible spring member. One or more dispensing heads can bedisposed adjacent the spindle and operative to apply one or morematerials and/or compounds on or along the flexible spring member to atleast partially form one or more of an indicia layer, an outer layer anda base layer such that a marking can be formed on or along a surface ofthe flexible spring member.

In some cases, one or more of the indicia of a marking according to anyone or more of the five (5) foregoing paragraphs can be at leastpartially formed from a quantity of colorant material that has acontrasting color to a color of the elastomeric material and is visuallyobservable by the human eye.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic representation of one example of a suspensionsystem of an associated vehicle that includes one or more gas springassemblies in accordance with the subject matter of the presentdisclosure.

FIG. 2 is a side view of one example of a gas spring assembly inaccordance with the subject matter of the present disclosure.

FIG. 3 is a cross-sectional side view of the gas spring assembly in FIG.2 taken from along line 3-3 therein.

FIG. 4 is an enlarged view of the portion of the flexible spring memberof the gas spring assembly shown in FIGS. 2 and 3 that is identified asDetail 4 in FIG. 3.

FIG. 4A is an enlarged view of an alternate configuration of the portionof the flexible spring member shown in FIG. 4.

FIG. 5 is a front elevation view of one example of a system applyingindicia along an exterior surface of a flexible spring member inaccordance with the subject matter of the present disclosure.

FIG. 6 is a side elevation view, in partial cross-section, of the systemand flexible spring member in FIG. 5 with the partial cross-sectiontaken from along line 6-6 thereof.

FIG. 7 is a front elevation view of another example of a system applyingindicia along an exterior surface of a flexible spring member inaccordance with the subject matter of the present disclosure.

FIG. 8 is a side elevation view, in partial cross-section, of the systemand flexible spring member in FIG. 7 with the partial cross-sectiontaken from along line 8-8 thereof.

FIG. 9 is a graphical representation of one example of a method ofmanufacturing a gas spring assembly in accordance with the subjectmatter of the present disclosure.

DETAILED DESCRIPTION

Turning now to the drawings, it is to be understood that the showingsare for purposes of illustrating examples of the subject matter of thepresent disclosure and are not intended to be limiting. Additionally, itwill be appreciated that the drawings are not to scale and that portionsof certain features and/or elements may be exaggerated for purposes ofclarity and/or ease of understanding.

FIG. 1 illustrates one example of a suspension system 100 disposedbetween a sprung mass, such as an associated vehicle body BDY, forexample, and an unsprung mass, such as an associated wheel WHL or anassociated axle AXL, for example, of an associated vehicle VHC. It willbe appreciated that any one or more of the components of the suspensionsystem can be operatively connected between the sprung and unsprungmasses of the associated vehicle in any suitable manner. Additionally,it will also be appreciated that such a suspension system of the vehiclecan also, optionally, include a plurality of damping members, such asdampers DMP, for example, and that any such damping members can also beoperatively connected between the sprung and unsprung masses of theassociated vehicle in any suitable manner.

The suspension system can also include a plurality of gas springassemblies supported between the sprung and unsprung masses of theassociated vehicle. In the arrangement shown in FIG. 1, suspensionsystem 100 includes four gas spring assemblies 102, one of which isdisposed toward each corner of the associated vehicle adjacent acorresponding wheel WHL. However, it will be appreciated that any othersuitable number (e.g., one or more) of gas spring assemblies couldalternately be used in any other configuration or arrangement. As shownin FIG. 1, gas spring assemblies 102 are supported between axles AXL andbody BDY of associated vehicle VHC. Additionally, it will be recognizedthat the gas spring assemblies shown and described in FIG. 1 (e.g., gasspring assemblies 102) are illustrated as being of a rolling lobe-typeconstruction. It is to be understood, however, that gas springassemblies of any other type, kind and/or construction could alternatelybe used, such as a convoluted bellows-type construction (not shown), forexample.

Suspension system 100 also includes a pressurized gas system 104operatively associated with the gas spring assemblies for selectivelysupplying pressurized gas (e.g., air) thereto and selectivelytransferring pressurized gas therefrom. In the exemplary embodimentshown in FIG. 1, pressurized gas system 104 includes a pressurized gassource, such as a compressor 106, for example, for generatingpressurized air or other gases. A control device, such as a valveassembly 108, for example, is shown as being in communication withcompressor 106 and can be of any suitable configuration or arrangement.In the exemplary embodiment shown, valve assembly 108 includes a valveblock 110 with a plurality of valves 112 supported thereon. Valveassembly 108 can also optionally include a suitable exhaust, such as amuffler 114, for example, for venting pressurized gas from the system.Optionally, pressurized gas system 104 can also include a reservoir 116in fluid communication with the compressor and/or valve assembly 108 andsuitable for storing pressurized gas.

Valve assembly 108 is in communication with gas spring assemblies 102through suitable gas transfer lines 118. As such, pressurized gas can beselectively transferred into and/or out of the gas spring assembliesthrough valve assembly 108 by selectively operating valves 112, such asto alter or maintain vehicle height at one or more corners of thevehicle, for example.

Suspension system 100 can also include a control system 120 that iscapable of communication with any one or more systems and/or components(not shown) of vehicle VHC and/or suspension system 100, such as forselective operation and/or control thereof. Control system 120 caninclude a controller or electronic control unit (ECU) 122communicatively coupled with compressor 106 and/or valve assembly 108,such as through a conductor or lead 124, for example, for selectiveoperation and control thereof, which can include supplying andexhausting pressurized gas to and/or from gas spring assemblies 102.Controller 122 can be of any suitable type, kind and/or configuration.

Control system 120 can also, optionally, include one or more height (ordistance) sensing devices (not shown in FIG. 1), such as, for example,may be operatively associated with the gas spring assemblies and capableof outputting or otherwise generating data, signals and/or othercommunications having a relation to a height of the gas springassemblies or a distance between other components of the vehicle. Suchheight sensing devices can be in communication with ECU 122, which canreceive the height or distance signals therefrom. The height sensingdevices can be in communication with ECU 122 in any suitable manner,such as through conductors or leads 126, for example. Additionally, itwill be appreciated that the height sensing devices can be of anysuitable type, kind and/or construction.

One example of a gas spring assembly including a flexible spring memberin accordance with the subject matter of the present disclosure is shownin FIGS. 2 and 3 as gas spring assembly 200, such as may be suitable foruse as one or more of gas spring assemblies 102 in FIG. 1, for example.Gas spring assembly 200 is shown as having a longitudinally-extendingaxis AX (FIG. 3) and can include one or more end members, such as an endmember 202 and an end member 204 that is spaced longitudinally from endmember 202. A flexible spring member 206 can extend peripherally aroundaxis AX and can be secured between the end members in a substantiallyfluid-tight manner such that a spring chamber 208 (FIG. 3) is at leastpartially defined therebetween.

Gas spring assembly 200 can be disposed between associated structuralcomponents, such as the sprung and unsprung masses of an associatedvehicle, for example, in any suitable manner. As one example, one endmember can be operatively connected to the associated sprung mass withthe other end member disposed toward and operatively connected to theassociated unsprung mass. In the embodiment shown in FIGS. 2 and 3, forexample, end member 202 is secured along a first or upper structuralcomponent USC, such as could represent associated vehicle body BDY inFIG. 1, for example, and can be secured thereon in any suitable manner.For example, one or more securement devices, such as mounting studs 210,for example, can be included along end member 202. In some cases, theone or more securement devices (e.g., mounting studs 210) can projectoutwardly from end member 202 and can be secured thereon in a suitablemanner, such as, for example, by way of a flowed-material joint (notshown) or a press-fit connection (not identified). Additionally, suchone or more securement devices can extend through mounting holes HLS(FIG. 3) in upper structural component USC and can receive one or morethreaded nuts 212 or other securement devices, for example. As analternative to one or more of mounting studs 210, one or more threadedpassages (e.g., blind passages and/or through passages) could be used inconjunction with a corresponding number of one or more threadedfasteners.

Additionally, one or more fluid communication ports can optionally beprovided to permit fluid communication with spring chamber 208, such asmay be used for transferring pressurized gas into and/or out of thespring chamber, for example. In the exemplary embodiment shown, atransfer passage 214 (FIG. 3) extends through at least one of mountingstuds 210 and is in fluid communication with spring chamber 208. It willbe appreciated, however, that any other suitable fluid communicationarrangement could alternately be used.

End member 204 can be secured along a second or lower structuralcomponent LSC, such as could represent associated axle AXL in FIG. 1,for example, in any suitable manner. As one example, lower structuralcomponent LSC could include one or more mounting holes HLS (FIG. 3)extending therethrough. In such case, a mounting stud 216 could beoperatively connected to end member 204 and could extend through one ofmounting holes HLS to receive a corresponding threaded nut 218, forexample.

It will be appreciated that the one or more end members can be of anysuitable type, kind, construction and/or configuration, and can beoperatively connected or otherwise secured to the flexible spring memberin any suitable manner. In the exemplary arrangement shown in FIGS. 2and 3, for example, end member 202 is of a type commonly referred to asa bead plate that is secured to a first end 220 of flexible springmember 206 using a crimped-edge connection 222. End member 204 is shownin the exemplary arrangement in FIGS. 2 and 3 as being of a typecommonly referred to as a piston (or a roll-off piston) that has anouter side wall 224 that abuttingly engages flexible spring member 206such that a rolling lobe 226 is formed therealong. As gas springassembly 200 is displaced between extended and collapsed conditions,rolling lobe 226 is displaced along outer side wall 224 in aconventional manner.

As identified in FIG. 3, end member 204 extends generally between afirst or upper end 228 and a second or lower end 230. One example of aconnection between the flexible spring member and the end member isshown as including a second end 232 of flexible spring member 206 beingsecured on or along upper end 228 of end member 204 using an end closure234. The end closure can be secured on or along end member 204 in anysuitable manner. In the exemplary embodiment shown, a retaining nut 236is threadably secured on mounting stud 216 and engages end closure 234.By securing mounting stud 216 on end member 204, such as by using athreaded nut 238, for example, the end closure can be drawn tight toupper end 228 to thereby secure second end 232 of the flexible springmember therebetween. In a preferred arrangement, a substantiallyfluid-tight seal can be formed between flexible spring member 206, suchas along second end 232 thereof, for example, and at least one of endmember 204 and end closure 234. It is to be understood, however, thatthe arrangement shown and described is merely exemplary and that anyother suitable construction and/or configuration can alternately beused.

A jounce bumper 240 can, optionally, be supported within spring chamber208, such as to inhibit direct contact between end members 202 and 204,for example. It will be appreciated that the jounce bumper, if included,can be supported on or along an end member in any suitable manner. Forexample, jounce bumper 240 is shown as being received on and retained byretaining nut 236.

A height or distance sensing device 242 is, optionally, shown in FIG. 3as being disposed within spring chamber 208 along end member 202 andbeing secured thereto using suitable fasteners 244. Height sensingdevice 242 can be of any suitable type, kind and/or construction, suchas an ultrasonic sensor that transmits and receives ultrasonic wavesWVS, for example. Additionally, it will be appreciated that heightsensing device 242 can be connected to other systems and/or componentsof a vehicle suspension system in any suitable manner. As shown in FIG.3, height sensing device 242 includes a lead or connection 246 that canbe used for such communication purposes, such as is indicated by leads126 of control system 120 in FIG. 1, for example.

Flexible spring member 206 can include a flexible wall 247 that canextend between longitudinally between ends 220 and 232 and peripherallyabout axis AX to at least partially define spring chamber 208. It willbe appreciated that flexible wall 247 can be formed in any suitablemanner and from any suitable material or combination of materials, suchas by using or otherwise including one or more fabric-reinforced,elastomeric plies or layers (not shown) and/or one or moreun-reinforced, elastomeric plies or layers (not shown), for example.Typically, one or more fabric-reinforced, elastomeric plies and one ormore un-reinforced, elastomeric plies will be used together and formedfrom a common elastorneric material, such as a synthetic rubber, anatural rubber or a thermoplastic elastomer. In other cases, however, acombination of two or more different materials, two or more compounds ofsimilar materials, or two or more grades of the same material could beused. In any case, the elastomeric material or materials from which theplies are formed will have certain material and/or mechanicalproperties, such as a durometer or hardness property, for example.

As identified in FIG. 4, flexible wall 247 includes an outer or coverply 248, an inner or liner ply 250, and two reinforcing plies 252 and254. The reinforcing plies can be of any suitable construction and/orconfiguration. For example, reinforcing plies 252 and 254 can includeone or more lengths of filament material that are at least partiallyembedded therein. It will be appreciated that the one or more lengths offilament material can be of any suitable type, kind and/or construction,such as monofilament polymeric strands, braided cotton yarn or bundledcarbon fibers, for example. Furthermore, such one or more lengths offilament material could optionally be coated or otherwise treated, suchas, for example, to improve adhesion with the adjacent plies or othersurrounding material. For example, the filament material could be rubbercoated, such that upon applying a layer of rubber over the filamentmaterial improved adhesion between the various layers could resultduring and/or after vulcanization, for example. Additionally, the one ormore lengths of filament material can be oriented in any suitablemanner, such as, for example, by having the filaments of one plydisposed at one bias angle and the filaments of another ply disposed ata different bias angle.

Additionally, a flexible spring member in accordance with the subjectmatter of the present disclosure can, optionally, include one or moremounting beads disposed along an end of the flexible wall. Asillustrated in FIG. 3, flexible spring member 206 is shown as includingtwo mounting bead with a mounting bead 256 disposed along end 220 and amounting bead 258 disposed along end 232. Additionally, a flexiblespring member in accordance with the subject matter of the presentdisclosure can, optionally, include at least one annular reinforcingelement 260 embedded within one or more of the ends of the flexiblewall, such as along the mounting beads thereof, for example.

Flexible wall 247 is shown as including an outer surface 262 and aninner surface 264, which can at least partially define spring chamber208. In some cases, at least a portion of outer surface 262 canabuttingly engage outer side wall 224 of end member 204, such as mayoccur in connection with rolling-lobe constructions, for example.

Gas spring assemblies in accordance with the subject matter of thepresent disclosure, such as gas spring assemblies 102 and 200, forexample, differ from conventional gas spring assemblies, at least, inthat a gas spring assembly in accordance with the subject matter of thepresent disclosure includes a flexible spring member with a flexiblewall or flexible wall portion that is marked with one or more indicia inone or more areas of the flexible wall or portion thereof. The one ormore markings, which can include one or more indicia in the one or moreareas, are are formed from two or more layers of material that aredisposed on or along at least a portion of a surface of the flexiblewall. Non-limiting examples of indicia can include any number and/orcombination of one or more of graphics, logos, symbols, machine-readabledata representations (e.g., bar codes, 2D data matrices), text and/orother identifying information, such as may take the form ofalpha-numeric or other characters, for example.

In the arrangement shown in FIGS. 2-4, for example, flexible springmember 206 of gas spring assembly 200 includes a marking 266 in the formof a plurality of indicia (e.g., alphabetic characters) that arearranged to form the FIRESTONE® trademark. It will be appreciated,however, that any combination of other graphics, logos, symbols,machine-readable representations, text, numbers, characters and/or otheridentifying information could additionally, or alternately, be included.Additionally, it will be appreciated that the one or more markings canbe disposed in any number of one or more areas on or along the innerand/or outer surfaces of the flexible spring member, such as markingsdisposed in peripherally-spaced and/or axially-spaced relation to oneanother.

The one or more markings that can be formed on or along the outersurface of a flexible spring member in accordance with the subjectmatter of the present disclosure can be formed from or otherwise includetwo or more coatings, applications, deposits and/or layers (any one ormore of which may be referred to herein as “layers” either individuallyor in combination) of material that are disposed in at least partiallyoverlapping relation to one another. That is, the two or more layers ofmaterial can be built-up overtop of one another on or along an area ofthe flexible spring member to form a marking in accordance with thesubject matter of the present disclosure. In a preferred arrangement,one layer of material will be substantially encapsulated by one or moreother layers of material. It will be appreciated, however, that otherconfigurations and/or arrangements could alternately be used.

As one non-limiting example, FIGS. 2-4 illustrate flexible spring member206 with marking 266 that includes an indicia layer 268 and an outerlayer 270. Indicia layer 268 includes one or more graphics, logos,symbols, machine-readable data representations, text (e.g., alphabetic,numeric and/or other characters) and/or other identifying informationformed from one or more inks, dyes, paints, stains and/or othercolorants having one or more colors, and/or from one or more appliquesand/or other sheet materials having one or more colors. In a preferredarrangement, one or more of the colors in indicia layer 268 will becolors that are different than the color of outer surface 262 offlexible wall 247 of flexible spring member 206. And, in a morepreferred arrangement, the one or more colors of indicia layer 268 willhave a substantially high contrast and/or visibility to the human eyerelative to the color of outer surface 262, such as white-on-black,red-on-black and/or yellow-on-black, for example. In this manner, theindicia formed on or along indicia layer 268 can, in a preferredarrangement, be visually observable on the flexible spring member of thegas spring assembly.

Outer layer 270 is shown in FIGS. 2-4 as being disposed over top ofindicia layer 268 and extending axially between layer edges 272 and 274.In a preferred arrangement, layer edges 272 and 274 are disposed axiallyoutwardly of indicia layer 268. Additionally, outer layer 270 can, insome cases, extend peripherally about all or substantially all of outersurface 262 between layer edges 272 and 274. That is, outer layer 270can, in some cases, form an endless annular layer or band aroundflexible spring member 206. In other cases, outer layer 270 can extendbetween peripherally-spaced layer ends 276 and 278. It will beappreciated, however, that, in such case, layer ends 276 and 278 arespaced peripherally outwardly from indicia layer 268, such as is shownin FIG. 2, for example.

Additionally, or in the alternative, a marking (e.g., marking 266) inaccordance with the subject matter of the present disclosure can,optionally, include a base layer 280 at least a portion of which isdisposed on or along outer surface 262 of flexible spring member 206. Ifprovided, base layer 280 can extend axially between layer edges 282 and284. In some cases, base layer 280 can extend peripherally about all orsubstantially all of outer surface 262 between layer edges 282 and 284.In other cases, base layer 280 can extend between peripherally-spacedlayer ends 286 and 288. In a preferred arrangement, layer edges 282 and284 of base layer 280, if provided, can be disposed axially outwardly ofindicia layer 268 such that the indicia layer is disposed on or alongthe base layer. Base layer 280 can be formed from any suitable compound,material or combination of compounds and/or materials.

As indicated above, base layer 280, if provided, can expand on or alongthe outer surface of the flexible wall of the flexible spring member. Ina preferred arrangement, base layer 280 is disposed in direct contactwith outer surface 262 of flexible wall 247 of flexible spring member206. In this manner, the base layer can inhibit or at least reduce thecontamination, discoloration and/or degradation of indicia layer 268 byoils, waxes and/or other compounds that may reside in or may otherwisebe components of the flexible materials (e.g., natural rubbers,synthetic rubbers and/or thermoplastic elastomers) from which theflexible wall is at least partially formed. In some cases, base layer280 can inhibit or at least reduce the migration of such oils, waxesand/or other compounds out of the material of the flexible wall. In thismanner, base layer 280 can, in some cases, function to lock-in orotherwise retain such oils, waxes and/or other compounds within thematerial of the flexible wall of the flexible spring member.

Outer layer 270 can be disposed on or along at least a portion ofindicia layer 268 such that the indicia layer is at least partiallycovered by the outer layer. In a preferred arrangement, however, outerlayer 270 will substantially-entirely cover indicia layer 268 and willbe disposed in direct contact with outer surface 262 of the flexiblewall and/or another layer of marking 266, such as base layer 280, forexample. In this manner, indicia layer 268 can be substantially-entirelyencapsulated by the outer layer together with any additional layers ofmarking 266 that may be included.

As a non-limiting example, outer layer 270 of marking 266 is identifiedin FIG. 4 as having a portion 290 disposed in direct contact withindicia layer 268, a portion 292 disposed toward layer edge 272 indirect contact with base layer 280 and a portion 294 disposed towardlayer edge 274 in direct contact with base layer 280. In such case,indicia layer 268 can be substantially encapsulated between outer layer270 and base layer 280. Additionally, or in the alternative, outer layer270 can, optionally, include a portion 296 adjacent layer edge 272 indirect contact with outer surface 262 of flexible spring member 206 anda portion 298 adjacent layer edge 274 in direct contact with the outersurface of the flexible spring member. In cases in which base layer 280is not provided, portions 296 and 298 of outer layer 270 cansubstantially encapsulate indicia layer 268. It will be appreciated thatouter layer 270 can be formed from any compound, material or combinationof compounds and/or materials that may be suitable for protecting theindicia layer and/or otherwise inhibiting or at least reducingcontamination, discoloration and/or degradation of the indicia layersuch as may occur due to exposure to matter such as water, salt, dirtand other compounds as well as exposure to atmospheric conditions suchas oxygen (O₂), ozone (O₃) and/or UV radiation. In a preferredarrangement, outer layer 270 can be formed from a transparent and/ortranslucent material such that the one or more indicia of indicia layer268 can be visually observed by the human eye through the outer layer.

An alternate arrangement of flexible spring member 206 is illustrated inFIG. 4A and is identified as flexible spring member 206′ that includes aflexible wall 247′ with outer or cover ply 248, inner or liner ply 250,and reinforcing plies 252 and 254. Flexible spring member 206′ is alsoshown as including outer surface 262 and inner surface 264 with amarking 266′ in accordance with the subject matter of the presentdisclosure disposed along outer surface 262. Marking 266′ includes anindicia layer 268 and an outer layer 270, such as have been describedabove in detail. Marking 266′ can also include a base layer 300′ that isdisposed on or along flexible wall 247′ of flexible spring member 206′.Base layer 300′ can include opposing surfaces 302′ and 304′ and canextend axially between layer edges 306′ and 308′. In some cases, baselayer 300′ can extend peripherally about all or substantially all offlexible spring member 206′ between layer edges 306′ and 308′. In othercases, base layer 300′ can extend between peripherally-spaced layer ends(not shown), such as have been illustrated in FIG. 2 by layer ends 286and 288 of base layer 280, for example. In a preferred arrangement,layer edges 306′ and 308′ of base layer 300′ can be disposed axiallyoutwardly of indicia layer 268 such that the indicia layer issubstantially-entirely disposed on or along the base layer. It will beappreciated that, in some cases, base layer 280 can be used togetherwith base layer 300′ and that, in other cases, base layer 300′ may beused as an alternative to base layer 280.

Base layer 300′ differs from base layer 280 in that base layer 300′ isformed from a length or section of flexible material, such as a naturalrubber, synthetic rubber or thermoplastic elastomer, for example, thathas properties and/or characteristics suitable for inhibiting or atleast reducing the migration of such oils, waxes and/or other compoundsout of the material of flexible wall 247′ of flexible spring member206′. In some cases, base layer 300′ may be formed from a compound,material or combination of compounds and/or materials that containreduced levels of oils, waxes and/or other elements, which may minimizethe migration of such elements into indicial layer 268. Additionally,base layer 300′ can, in some cases, be formed from a material that canbe assembled together with the other plies of flexible wall 247′ in anuncured condition and cured (e.g., vulcanized) together with the otherplies to form a finished flexible wall or flexible wall assembly offlexible spring member 206′. In such case, base layer 300′ may be atleast partially embedded within an adjacent ply of the flexible wall,such as ply 248 of flexible wall 247′ as is shown in FIG. 4A, forexample. In such an arrangement, surface 304′ and at least a portion oflayer edges 306′ and 308′ can be disposed in direct contact with ply 248of flexible wall 247′. In other cases, base layer 300′ can be secured onor along the outer surface of the flexible spring member in a suitablemanner, such as by way of a flowed-material joint (not shown), forexample. In such cases, surface 304′ can be disposed in abuttingengagement with outer surface 262 of the flexible spring member.

It will be appreciated that layers 268, 270, 280 and 300′ are shown inFIGS. 2-4A as having exaggerated dimensions and spacing for purposes ofease of identification and understanding. The layers are not to scaleand are, as described herein, generally intended to be in direct contactwith one another. As such, it is to be understood that the spaces shownbetween adjacent layers are merely to permit easy identification ofindividual layers and is not intended to illustrate a combination oflayers that are disposed in spaced-apart relation to one another.

Is it will be appreciated that layers 268, 270, 280 and/or 300′ can takeany suitable form or configuration and can be applied on or along theflexible spring member in any suitable manner. As one example, layers268 and 270 as well as layer 280, if provided, can be applied as liquidor semi-solid compounds. As another example, layers 268 and 270 as wellas one or more of layers 280 and 300′ can take the form of one or moresections of sheet material that are applied along and adhered to orotherwise disposed along the outer surface of the flexible springmember. As a further example, layers 268, 270, 280 and/or 300′ can beformed from a combination of liquid or semi-solid compounds and one ormore sections of sheet material.

One example of a system 400 that is suitable for forming a marking inaccordance with the subject matter of the present disclosure (e.g.,marking 266) on or along a flexible spring member (e.g., flexible springmember 206 and/or 206′) is shown in FIGS. 5 and 6. System 400 includes abase 402 having a spindle 404 that is rotatably supported on the base. Amotor 406 can drivably engage spindle 404 to rotate the spindle aroundan axis AXR relative to base 402, such as is represented in FIG. 5 byarrows RT1 and RT2. System 400 also includes support members 408 and 410that are supported on or along spindle 404, and can be secured theretoin a manner suitable for rotation of the support members with thespindle. Support members 408 and 410 also include outer surfaces 412 and414, respectively, that are dimensioned to receive and abuttingly engagethe opposing ends of a flexible spring member. In the arrangement shownin FIGS. 5 and 6, flexible spring member 206 is shown as being disposedin abutting engagement with the support members with end 220 disposedalong outer surface 412 and end 232 disposed along outer surface 414. Itwill be appreciated, however, that other configurations and/orarrangements could alternately be used.

System 400 can also include one or more dispensing heads that may besuitable for spraying, dispensing or otherwise applying a liquid orsemi-solid compound or material on or along the outer surface of theflexible spring member. In the arrangement shown in FIGS. 5 and 6,system 400 includes a dispensing head 416 suitable for spraying,dispensing or otherwise applying compounds and/or materials suitable forforming an indicia layer (e.g., indicia layer 268) on or along theflexible spring member. System 400 can also include a dispensing head418 suitable for spraying, dispensing or otherwise applying compoundsand/or materials suitable for forming an outer layer (e.g., outer layer270) overtop of or otherwise at least partially covering the indicialayer. In some cases, system 400 can, optionally, include a dispensinghead 420 suitable for spraying, dispensing or otherwise applyingcompounds and/or materials suitable for forming a base layer (e.g., baselayer 280) on or along the outer surface of the flexible spring member.It will be appreciated that rotation of the flexible spring member inthe direction indicated by arrow RT1 will result in the sequentialapplication of a base layer, an indicia layer and an outer layer, suchas has been described above in connection with marking 266.

As indicated above, indicia layer 268 can be formed from one or moreinks, dyes, paints, stains and/or other colorants having one or morecolors, and/or from one or more appliques and/or other sheet materialshaving one or more colors. One non-limiting example of a suitablecolorant for forming an indicia layer can include liquid colorant (e.g.,ink) that is formulated to be ejected or otherwise delivered throughconventional dispensing nozzles. As such, dispensing head 416 is shownas including a plurality of colorant reservoirs 422, 424, 426 and 428that are in fluid communication with a dispensing nozzle 430. In apreferred arrangement, reservoirs 422-428 contain different coloredcolorants (e.g., inks) that can be dispensed in any suitable manner toprint, mark or otherwise generate an indicia layer, such as indicialayer 268. System 400 can also include a control system 432 iscommunicatively coupled with motor 406 and dispensing heads 416, 418 and420. Control system 432 can selectively operate motor 406 to rotateflexible spring member 206 and can selectively actuate dispensing heads416, 418 and/or 420 to form the one or more layers of a marking inaccordance with the subject matter of the present disclosure.

Another example of a system 500 that is suitable for forming a markingin accordance with the subject matter of the present disclosure (e.g.,marking 266 or 266′) on or along a flexible spring member (e.g.,flexible spring member 206 and/or 206′) is shown in FIGS. 7 and 8.System 500 includes a base 502 having a spindle 504 that is rotatablysupported on the base. A motor 506 can drivably engage spindle 504 torotate the spindle around an axis AXR relative to base 502, such as isrepresented in FIG. 7 by arrows RT1 and RT2. System 500 also includes asupport member 508 that is supported on or along spindle 504, and can besecured thereto in a manner suitable for rotation of the support memberwith the spindle. Support member 508 includes an outer surface 510 thatis dimensioned to receive and abuttingly engage an end of a flexiblespring member. In the arrangement shown in FIGS. 7 and 8, flexiblespring member 206 is shown as being disposed in abutting engagement withthe support member with end 232 disposed along outer surface 510. Itwill be appreciated, however, that other configurations and/orarrangements could alternately be used.

System 500 can also include roller shafts 512 and 514 that are rotatablysupported on base 502 for rotation about axes AXS. Rollers 516 and 518can be respectively supported on or along rollers shafts 512 and 514. Insome cases, the rollers and/or roller shafts can be freely rotatableabout axes AXS. In other cases, however, one or more of the roller androller shaft combinations can be driven, such as by way of a motor 520,for example, which is shown in FIG. 8 as drivably engaging roller shafts512. A control system 522 can be communicatively coupled with motors 506and/or 520 for selective operation thereof, such as to rotate theflexible spring member about axis AXR of spindle 504.

Rollers 516 and 518 can include outer surfaces 524 and are preferablyspaced apart from one another such that a portion of flexible springmember 206 can be disposed therebetween. In a preferred arrangement, atleast one of the outer surfaces of rollers 516 and 518 will abuttinglyengage flexible spring member 206. In this manner, a pre-constructedmarking or a pre-constructed portion of a marking can be introducedbetween the outer surface of the flexible spring member and the outersurface of a roller such that the pre-constructed marking or portionthereof can be biased against the outer surface of the flexible springmember by the roller and thereby applied to the flexible spring member.In the arrangement shown in FIGS. 7 and 8, for example, at least aportion of a pre-constructed marking MRK is disposed between outersurface 262 of flexible spring member 206 an outer surface 524 of roller516. As flexible spring member 206 is rotated in the direction of arrowRT1, pre-constructed marking MRK is applied to the flexible springmember. System 500 can, optionally, include one or more dispensing headsthat may be suitable for spraying, dispensing or otherwise applying aliquid or semi-solid compound or material on or along the outer surfaceof the flexible spring member. In the arrangement shown in FIGS. 7 and8, system 500 includes dispensing heads 526 and 528 may be suitable forspraying, dispensing or otherwise applying compounds and/or materials,such as adhesives or bonding agents and/or such as may be suitable forforming an indicia layer (e.g., indicia layer 268), an outer layer 270and/or a base layer 280 on or along the flexible spring member.

FIG. 9 illustrates one example of a method 600 of manufacturing aflexible spring member, such as flexible spring member 206 and/or 206′,for example, that is suitable for use in forming a gas spring assembly,such as one of gas spring assemblies 102 (FIG. 1) and/or 200 (FIGS. 2and 3), for example. Method 600 can include providing a flexible springmember (e.g., flexible spring member 206) along which one or moremarkings are to be formed in accordance with the subject matter of thepresent disclosure, such as is represented by item number 602. Method600 can also include applying one or more indicia layers (e.g., indicialayer 266 and/or 266′) in one or more areas on or along a surface (e.g.,outer surface 262 and/or inner surface 264) of the flexible springmember, such as is represented by item number 604. Method 600 canfurther include applying one or more outer layers (e.g., outer layer270) in one or more areas on or along the surface of the flexible springmember and preferably at least partially covering one or more indicialayers, such as is represented in FIG. 9 by item number 606. Method 600can optionally include applying one or more base layers (e.g., baselayer 280 and/or 300′) prior to applying the one or more indicia layersand/or the one or more outer layers, such as is represented by itemnumber 608.

In some cases, method 600 can also, optionally include drying orotherwise securing one or more of the layers. Method 600 can furtherinclude providing one or more end members, such as one or more of endmembers 202 and/or 204, for example, such as is represented in FIG. 9 byitem number 610. Method 600 can also include securing the flexiblespring member to one or more of the end members (e.g., one or more ofend members 202 and/or 204), such as is represented by item number 612,for example.

As used herein with reference to certain features, elements, componentsand/or structures, numerical ordinals (e.g., first, second, third,fourth, etc.) may be used to denote different singles of a plurality orotherwise identify certain features, elements, components and/orstructures, and do not imply any order or sequence unless specificallydefined by the claim language. Additionally, the terms “transverse,” andthe like, are to be broadly interpreted. As such, the terms“transverse,” and the like, can include a wide range of relative angularorientations that include, but are not limited to, an approximatelyperpendicular angular orientation. Also, the terms “circumferential,”“circumferentially,” and the like, are to be broadly interpreted and caninclude, but are not limited to circular shapes and/or configurations.In this regard, the terms “circumferential,” “circumferentially,” andthe like, can be synonymous with terms such as “peripheral,”“peripherally,” and the like.

Furthermore, the phrase “flowed-material joint” and the like, if usedherein, are to be interpreted to include any joint or connection inwhich a liquid or otherwise flowable material (e.g., a melted metal orcombination of melted metals) is deposited or otherwise presentedbetween adjacent component parts and operative to form a fixed andsubstantially fluid-tight connection therebetween. Examples of processesthat can be used to form such a flowed-material joint include, withoutlimitation, welding processes, brazing processes and solderingprocesses. In such cases, one or more metal materials and/or alloys canbe used to form such a flowed-material joint, in addition to anymaterial from the component parts themselves. Another example of aprocess that can be used to form a flowed-material joint includesapplying, depositing or otherwise presenting an adhesive betweenadjacent component parts that is operative to form a fixed andsubstantially fluid-tight connection therebetween. In such case, it willbe appreciated that any suitable adhesive material or combination ofmaterials can be used, such as one-part and/or two-part epoxies, forexample.

Further still, the term “gas” is used herein to broadly refer to anygaseous or vaporous fluid. Most commonly, air is used as the workingmedium of gas spring devices, such as those described herein, as well assuspension systems and other components thereof. However, it will beunderstood that any suitable gaseous fluid could alternately be used.

It will be recognized that numerous different features and/or componentsare presented in the embodiments shown and described herein, and that noone embodiment may be specifically shown and described as including allsuch features and components. As such, it is to be understood that thesubject matter of the present disclosure is intended to encompass anyand all combinations of the different features and components that areshown and described herein, and, without limitation, that any suitablearrangement of features and components, in any combination, can be used.Thus it is to be distinctly understood claims directed to any suchcombination of features and/or components, whether or not specificallyembodied herein, are intended to find support in the present disclosure.

Thus, while the subject matter of the present disclosure has beendescribed with reference to the foregoing embodiments and considerableemphasis has been placed herein on the structures and structuralinterrelationships between the component parts of the embodimentsdisclosed, it will be appreciated that other embodiments can be made andthat many changes can be made in the embodiments illustrated anddescribed without departing from the principles hereof. Obviously,modifications and alterations will occur to others upon reading andunderstanding the preceding detailed description. Accordingly, it is tobe distinctly understood that the foregoing descriptive matter is to beinterpreted merely as illustrative of the subject matter of the presentdisclosure and not as a limitation. As such, it is intended that thesubject matter of the present disclosure be construed as including allsuch modifications and alterations.

The invention claimed is:
 1. A method of manufacturing a flexible springmember, said method comprising: providing a flexible spring memberincluding a flexible wall that is at least partially formed fromelastomeric material and has a surface; and, forming a marking havingone or more indicia along said surface, said action of forming a markingincluding: applying one or more quantities of colorant material alongsaid surface to form an indicia layer along said surface that at leastpartially forms the one or more indicia; and, applying a quantity ofmaterial along said surface to form an outer layer along said surfacedisposed overtop of said indicia layer such that said one or moreindicia are substantially encapsulated.
 2. A method according to claim1, wherein applying said one or more quantities of material along saidsurface to form said indicia layer include applying said one or morequantities of material on said surface, and applying said quantity ofmaterial along said surface to form said outer layer includes applyingsaid quantity of material on said surface outwardly beyond said indicialayer to substantially encapsulate said indicia layer between saidsurface of said flexible wall and said outer layer.
 3. A methodaccording to claim 1, wherein said action of forming a marking includesapplying a quantity of material along said flexible wall to form a baselayer along said surface, and forming said indicia layer along saidsurface includes applying said one or more quantities of material alongsaid base layer such that said base layer is interposed between saidelastomeric material of said flexible wall and said indicia layer.
 4. Amethod according to claim 3, wherein applying said quantity of materialalong said surface to form said outer layer includes applying saidquantity of material overtop of said indicia layer and along at least aportion of said base layer such that said indicia layer is substantiallyencapsulated between said outer layer and said base layer.
 5. A methodaccording to claim 4, wherein applying said quantity of material of saidouter layer overtop of said indicia layer and along at least a portionof said base layer includes applying said quantity of material of saidouter layer outwardly beyond said base layer and along said surface ofsaid flexible wall to substantially encapsulate said indicia layer andsaid base layer between said surface of said flexible wall and saidouter layer.
 6. A method according to claim 1, wherein at least one ofsaid actions of applying said one or more quantities of colorantmaterial to form said indicia layer and applying said quantity ofmaterial to form said outer layer includes dispensing a liquid orsemi-solid compound along said surface of said flexible wall.
 7. Amethod according to claim 1 further comprising providing at least apre-constructed portion of a marking including at least one of said oneor more quantities of colorant forming said indicia layer and saidquantity of material forming said base layer, and at least one of saidactions of applying said one or more quantities of colorant material toform said indicia layer and applying said quantity of material to formsaid outer layer includes securing said pre-constructed portion of saidmarking along said surface of said flexible wall.